ZA001 to be donated to Japanese museum

Screen Grab from Flightradar24

Dreamliner 1, the first Boeing 787 will fly to Boeing Field today after spending several years in storage in Palmdale, Ca.  The aircraft will subsequently fly to Japan, perhaps around the end of this month, where it will be donated to a yet un-named Japanese museum after removal of flight test equipment.  Much of the aircraft's primary structure was built in Japan including the wings. The second and third 787s were donated to the Pima Air Museum and Museum of Flight respectively.

Adjustments to 787 delivery schedule for September

Looks like there's some adjustment to the 787 delivery schedule for September.  Looks like the delivery of ZA246 (LN 208, VT-ANR) is being pushed back a bit but there isn't a new delivery date on this as of yet.

Also the line move in 40-24 has been delayed as engineers try to work an issue on ZB005 (LN 236, ZK-NZG) which requires it to be back inside.  There isn't any word on when the line move will pule to allow the next aircraft to start final assembly.

Meanwhile ZA817 (LN 241, N800AN) for American Airlines is sitting in position 3 in 40-26 still waiting for its engines to be attached.  There is some unknown issue and the first 787 for American won't have them hung until next week.

ZA003, the third 787-8 test flight aircraft, was also flown to Boeing Field earlier today as it is going to be prepared for display at Seattle's Museum of Flight.  No word on the fate of the other two undeliverable test airplanes but I wouldn't be surprised if they end up in Museums as well.  I doubt that they would be exhibited with actual engines as that would be expensive.

At this rate it does appear that Boeing will not make 10 deliveries this month and may have to settle for 9 or fewer.

Lastly, some anonymous readers have sent me pictures of ZA006 on the Charleston flight line and I'd like to share them with you.

Photo by Anonymous

Photo by Anonymous

Photo by Anonymous

Photo by Anonymous

Photo by Anonymous

Photo by Anonymous

Photo by Anonymous

787 Full Production Table

787 Current Production Table

Delivered 787 List

787 Production and Delivery Trends

787 Monthly Delivery Tracking

Current 787 Operators

Total 787 Deliveries By Customer

2014 Projected 787 Deliveries

787-9 Flight Testing Tracker

First SC built 787 scheduled to fly this Friday

It's looking like Boeing is setting to fly the first Charleston built 787 this Friday. Randy Neville, a Boeing 787 test pilot fresh from the 787 World Tour flew ZA003 from St. Louis today then left for Charleston in order to take ZA237 (LN46) on its first flight scheduled for May 18th.  Randy was on ZA001 when it went up on its first flight on Dec. 15, 2009.  Now he's tasked with taking this very special 787 into the South Carolina skies.  This airplane should deliver in mid to late June.

Currently Boeing is conducting tests on ZA506 (LN47) which is destined for ANA.  However current information is that this airplane and ZA507 (LN48) will not deliver this month and is more likely to deliver in June.  This means that only ZA233 (LN29, VT-AND) will deliver this month to Air India.

Meanwhile Boeing had its Investors Day conference today.  There was no new information out of today's conference though it seems that Boeing is now studying a 787 production rate greater than 10.  They're still planning for a rate increase this fall to 5/month.

787 update 12/1/2011

With all the excitement over yesterday's Boeing-IAM contract extension, there wa also news about the 787 that has come out and I would like to recap here.

787-GEnx certification

Boeing is still about 95% complete with 787-GEnx-1B certification testing according to Jim Albaugh who spoke at a Credit Suisse conference in NY yesterday. Certification testing using ZA005 and ZA006 are more or less complete according to Flightblogger, in a post on Nov. 29th. Additionally, he reported that ZA006 is getting some test equipement removed pior to be sent to San Antonio for refurbishment into a customer aircraft. If the change incorporation being done on production aircraft is any indication then this work on ZA006 is likely to take quite a bit of time to complete.

Boeing has done some of the F&R testing on the test aircraft but has to do the rest on a production standard aircraft. The 787 that has been tasked for this work is L/N 35 which is a 787 to be delivered to Air India. According to Flightblogger, first flight of this airplane has been delayed to around the middle of December owing to the slower pace of change incorporation on the 787s. Because of the delay in getting the needed aircraft, delivery of the first GEnx-1B 787 has slipped to January of 2012. The first one will be delivered to Japan Airlines, probably L/N 23, ZA177 which just returned form San Antonio after undergoing change incorporation work. Just yesterday the GEnx-1B engines received it ETOPS 330 certification however both the Trent and GEnx engines in combination with the 787 airframe won't be certified for ETOPS 330 until a fix to the fuel monitoring software is implemented, tested and certified by the FAA.

ZA004 - Trent Package "B" testing

According to Guy Norris, Boeing has completed certification testing for the Trent 1000 package "B" improvements for the 787. This will allow Boeing to finally start to deliver 787 with the new Trents which bring the specific fuel consumption to within 1% of the original promised specs. Boeing had undertaken this testing using ZA004. Over the last few weeks this airplane has been flown several times a day in order to finish up all the requirements. Once the FAA has received and approved all the test data, Boeing should be able to start delivering 787s with this engine. L/N 31 will be the first 787 to be delivered with the package "B" Trent 1000 engines.

Future deliveries

The pace of deliveries is obviously being didtaced by the pace of change incorporation which is excrutiatingly slow right now. The pace has already pushed the GEnx 787 deliveries out to January as well as deliveries to Trent 1000 customers further to the right. ANA was supposed to have received 5 787 in December...it will only receive two (L/N 31 and L/N 41). Both these airplanes are Trent 1000 package "B" airplanes. There are two other ANA 787s that have their engines attached and being prepped for delivery. These are L/N 9 (ZA102, JA804A) which was just pulled out to the Everett fuel dock and L/N 42 (ZA105, JA808A) which is still in front of the EMC.

These airplanes are not due to be delivered until after January 1st but there are now more 787s appearing on the flightline in preparation for delivery which is a good sign but on the flip side most of the aircraft that are out on the flightline are very early build airplanes that need extensive re-work done before they can be delivered to customer. Just to get these 11 airplanes (L/N 7 to L/N 19) done would probably take a good 2 years. Most of the deliveries will come from the late builds, particularly L/N 30 on up.

Production and Ramp Up

Jim Albaugh gave a nice update on the status of 787 production and ramp up. Currently they are are still at producing at 2.5 787 per month with the aim of ramping to 3.5 by around March or April and then to 5 by the end of 2012. Boeing is still maintaining it guidance of 10 787s per month by the end of 2013.

Albaugh had very good things to report about the North Charleston plant. The first aircraft from that line should deliver before June of 2012. The plant is capable of producing 2.5 787 per month right now. Boeing has now opened up the delivery center as well as the 787 interiors fabrication plant to supply bins, partitions, crew rest areas, etc. for the Charleston built 787s.

Test Flight Fleet

Now that test flights are nearing the end (at least for the 787-8), Boeing is starting to make plans for the first three airplanes built. ZA004-ZA006 will be refurbished and sold to customers (BBJ). Boeing has flown ZA001, the first 787, to Palmdale Airport where it will be in storage until they figure out which museum to house it in. Likely candidates are the Museum of Flight in Seattle or the Future of Flight museum in Everett though I wouldn't count out the NASM (National Air and Space Museum) in Virginia out. ZA002 is going to be in Charleston, SC for some time for testing purposes but its long term fate is unclear. ZA003 is due to start a 6 month tour of the 787 on December 5th. First stop is China an other Asian and African countries whose airlines have bought the 787. After the tour is completed the aircraft's long term fate is also undecided. No doubt there would be some testing to be done, particularly on engine and airframe improvements to lower weight and increase fuel efficiency and reduce the noise footprint. This is why ZA002 and ZA003 will probably held by Boeing for the foreseeable future to serve as test beds for these improvements.

787 production continues; Boeing draw first blood in Dubai

With Dubai 2011 underway, Boeing has drawn first blood with a huge order from Emirates.

But first some 787 tidbits.

Boeing sent two of it's 787 test planes on international marketing trips. ZA001 is flying to various 787 customer destinations to show the aircraft around the world. First stop is New Zealand where Air New Zealand is to induct the first 787-9 into it's fleet in a little over 2 years from now. It will go on to Australia from there where Jetstar and QANTAS will take delivery starting in 2013. ZA003 is now flying with a full passenger interior with the test workstations and other flight test equipment removed. It also is sporting a new paint job which is a hybrid of the Dreamliner livery that Boeing painted on ZA001.

Meanwhile, back in Boeing has pushed another 787 out the door and has reallocated several 787 to other airlines. L/N 50 and L/N 51 are currently on the final assembly floor and each has been reallocated to United and ANA respectively . They were to have gone to Ethiopian and LAN but were changed for unknown reasons. With the start of assembly on L/N 51 Boeing is on it's way of 2.5 787s per month with the target of 3.5 to occur sometime in early 2012.

One of the early build 787s appears to have completed the change incorporation and re-work. That airplane is L/N 23 (ZA177) which is destined for Japan Airlines. The aircraft took a check test flight on Nov. 11th and was ferried back to Everett on the 13th. It still does not have a customer interior but that work will be done in Everett along with testing of the interior and then Boeing and customer test flights prior to delivery. Given that work, Boeing can deliver this plane to JAL by the end of December or early January, 2012 depending on the remaining certification activities that need to be completed on the GEnx-1B powered 787. I am still maintaining my short term view that Boeing should be able to deliver 6 more 787 in December (no November deliveries). Most if not all these deliveries will be later production airplanes for ANA with a later production GEnx airplane added in.

Speaking of which, ZA006 continues F&R and ETOPS testing. Last word from Boeing was that GEnx-1B testing was 95% complete so I do anticipate that Boeing can complete all certification testing by the end of this month will the aim of having first delivery by the end of December to either JAL or Air India.





Dubai 2011


The Dubai Air Show got of to a bang with a huge order by Emirates for 50 777-300ERs. The bang not only came in the size of the order $18bn at list prices, or the fact that this is Boeing's largest commercial aircraft order by value or that it will make Emirates the largest user of the 777. The big bang came in the message this order sent to Airbus. It has been no secret that the market really hasn't accepted the A350-1000 as a viable competitor to the 777-300ER. The market response after launching the A350 coupled with the feeble attempt by Airbus and Rolls Royce to improve the aircraft earlier this year and the 2 year delay (with possibly more delays to come) has angered customers for the airplane, namely Qatar and Emirates. Thus this order at the start of the airshow was meant as a message to Airbus about the status of the A350-1000. Additionally, the A350-1000 is barely a better airplane than the Boeing offering but with the proposed 777-8X/9X (on which Emirates has been working closely with Boeing) thus this latest order would allow Emirates to easily introduce the next iteration of the 777 as this latest order is delivered towards the end of the decade. I wouldn't be surprised if Emirates has a conversion feature in the contract that allows them to convert to the newer model after Boeing launches the airplane with delivery aimed for 2020.


Airbus did get into the order column with an order for 50 A320NEOs from ALAFCO. This same lessor announced today that they sold 6 or their 787 orders to Oman Air. So this order with Oman is really a non-order order. Boeing is still adding more MoUs for the 737 MAX. The count is 700 airplanes spread across 9 customers with only American Airlines the only named customer of those 9. I don't expect any of these MoUs to be firmed before the end of the year but most if not all should be firmed by the end of 1st quarter 2012 in addition to any new customers that would have signed on by then.


Dubai 2011 Totals


Airbus


ALAFCO - 50 x A320NEO (+30 options)

Boeing

Emirates - 50 x 777-300ER (+20 options)

Boeing starts 787/Trent 1000 F&R and ETOPs Testing

Boeing announced the start of F&R/ETOPs testing today. The sole aircraft that is conducting the tests, ZA102, kicked the testing off yesterday with a seven hour and thirty minute flight along the west coast of the US. This airplane will be conducting all the F&R and ETOPs testing with the Trent 1000 engine.

This phase should last about 300 flight test hours after which Boeing should receive type certification and can proceed with deliveries to ANA around August or September. Given the amount of testing and allowing for maintenance, I anticipate that this final phase of testing should last about 45 days which means a mid August completion for the final phase of testing.

Boeing will still have to submit any remaining deliverables to the FAA and EASA and they would take at least a couple of weeks to issue the final type certification for the 787. Therefore, it is looking like an early to mid September delivery time frame for the 787 to ANA.

F&R is testing that measures the production aircraft's response to normal as well off-normal operations which would include simulated engine and systems failures. This testing is only to certify the Trent-1000/787 engine airframe combination.

Boeing is still in discussions with the FAA regarding F&R/ETOPs testing for the GEnx version. Until those discussions are completed it is unknown which aircraft(s) with the GEnx-1B engines will be used for those tests. It is anticipated that GE F&R/ETOPs should start around August. Given this time frame the GEnx powered 787 should be delivered to Japan Airlines around October.

Meanwhile Boeing is still using the other airplanes for testing purposes. ZA001 just returned from Europe and the Paris Air Show and will be spending a week at Boeing Charleston as workers prepare to load the first 787 into the tooling fixtures at that plant. ZA002 will be making the trip to Japan for service ready validation operational validation. That airplane will be there for about a week conducting those tests. ZA003 is conducting Boeing test flights to evaluate the hybrid laminar flow control system proposed for the 787-9. ZA004 is conducting nautical air miles tests (NAMS) using the package "B" Trent 1000 engines. This testing will be used to evaluate the improved fuel efficiency over the package "A" Trents. ZA005 and ZA006 will continue certification flight tests with the GEnx-1Bs.

Here's Boeing Press Release on the start of F&R/ETOPs:

Boeing Begins Final Phase of 787 Flight Testing

EVERETT, Wash., June 27, 2011 /PRNewswire/ -- Boeing (NYSE: BA) yesterday started Function & Reliability (F&R) testing and extended operations (ETOPS) demonstrations on the 787 Dreamliner. This is the final phase of flight testing prior to certification of the airplane.

"We are ready for this final phase of flight testing," said Scott Fancher, vice president and general manager of the 787 program. "The team has created a solid plan for accomplishing the hours and test points required for F&R and ETOPS testing in support of delivery to our customer ANA in the August to September time period."

F&R testing simulates various normal and non-normal operations for the airplane, in a realistic airline-like flight environment. ETOPS refers to extended operations – for twin jets, flights that are more than 60 minutes away from a suitable landing field. During ETOPS demonstrations the company validates the airplane's ability to safely divert for a variety of reasons, including long diversions with one engine shut down.

In addition to F&R and ETOPS testing for the 787 with Rolls-Royce engines, Boeing continues certification testing on 787s with General Electric engines and will conduct a separate F&R/ETOPS test program for that version of the airplane. Other activities will continue on the flight test fleet to support Boeing objectives including examining potential technologies for the 787-9 and testing engine improvement packages.

787 test flight fleet done

On the eve of the Paris Air Show, James Albaugh. President of Boeing Commercial aircraft, revealed that Boeing is done with 97% of the required testing on the Trent 1000 powered and that the Boeing test flight fleet ZA001- ZA006 would not be flying for certification purposes. Boeing still has to complete SROV activities in Japan early next month as well as start ETOPs/F&R testing using ZA102 (LN9) for the Trent-1000 engines.

It is unclear which GEnx powered 787 will be used to conduct the ETOPS/F&R testing for the GEnx version of the 787 though ZA177 a GE powered 787 is still in change incorporation and maybe a possible candidate to conduct those tests around August or September depending on the progress of its change incorporation. If not then the only option is for ZA005 or ZA006 to conduct those tests.

ZA102 was supposed to start F&R testing in early June but as of today it still has no started and now Boeing is saying late June for the start of testing. I have no word from sources as to the actual start date thus far.

Even though Boeing's 787 test flight fleet certification duties are over, their flight testing duties are on going with ZA004 undertaking NAMS (nautical air mile) testing with the package "B" Trent 1000 engines. ZA003 is testing the hybrid laminar flow control (HLFC) which, it is hoped, will reduce drag by delaying the transition of laminar air flow over the horizontal tail plane to turbulent air flow. If these tests are successful, then it is planned to introduce this system on the HTP for the 787-9 and possibly to the 787-8 as well. ZA001 will fly to Paris for the air show then on to Warsaw and Berlin for marketing related activities with Air Berlin and LOT. As mentioned earlier, ZA002 will be dispatched Japan for Service Ready Operational Validation Testing.

Below is the schedule for the SROV tests with ANA in Japan:

Flight 1 LV. SEA 7-3-11 5AM ARR. HND 7-4-11 6:30AM
Flight 2 LV. HND 7-5-11 6:30AM ARR. ITM 7-5-11 7:30AM
Flight 3 LV. ITM 7-5-11 11:30AM ARR. HND 7-5-11 12:30AM
Flight 4 LV. HND 7-6-11 6:30AM ARR. KIX 7-6-11 8:00AM
Flight 5 LV. KIX 7-6-11 12:00PM ARR. HND 7-6-11 1:30PM
Flight 6 LV. HND 7-7-11 6:00AM ARR. OKJ 7-7-11 7:30AM
Flight 7 LV. OKJ 7-7-11 11:00AM ARR. HND 7-7-11 12:30PM
Flight 8 LV. HND 7-7-11 3:00PM ARR. HIJ 7-7-11 5:00PM
Flight 9 LV. HIJ 7-7-11 7:00PM ARR. HND 7-7-22 8:30PM
Flight 10 LV. HND 7-9-11 1:00PM ARR. SEA 7-9-11 6:30AM

Ch...ch...ch...changes

ZA177 in San Antonio for Change Incorporation (Boeing Photos)

After flying ZA177 (LN 23 for Japan Air Lines) down to San Antonio (Lackland Air Force Base) last week, Boeing is now ready to start the process of change incorporation into the built 787s as well as incorporating the needed changes back into the supply chain.

First a little background. Throughout the testing and certification program (either ground test or flight tests) for the 787, Boeing and the FAA identified changes that needed to be made to the 787s in order for them to be certified to carry passengers. These changes can be numerous and each task can take anywhere from a few minutes to weeks to complete. The added complexity is that each task has to be undertaken in a certain order so as not to duplicate any disassembly tasks as well as not to cause any damage to the aircraft. The airplanes will not receive the customer interiors (seats, galleys, IFE, etc.) in San Antonio. That work will be done in Everett after the change incorporation process is completed.

Boeing said that a total of 6 787s will go through change incorporation in San Antonio including the last 3 787 flight test aircraft (ZA004, ZA005, and ZA006) which will be refurbished for delivery to unannounced customers. Boeing has not identified the other production 787 that will undergo change incorporation in San Antonio but has said that they send additional 787 to San Antonio for change incorporation work as they see the need. The other airplanes that are not flown to San Antonio will have work done at Everett. Currently Boeing has 35 787s assembled or are in the process of final assembly bu change incorporation will only occur on LN 4 and later. Currently that is 32 airplanes. As modifications are identified and the detailed engineering and design changes are finalized, they will be incorporated back though the final assembly process and into the supply chain (at least that's the plan). It is not known how long each aircraft will take in change incorporation. Here's Boeing's press release:

Boeing Begins Change Incorporation Work on 787 Dreamliner

787 program continues steady progress toward certification and delivery

EVERETT, Wash., March 7, 2011 /PRNewswire/ -- Today, Boeing (NYSE: BA) began change incorporation work on the 787 Dreamliner at Boeing's Global Services & Support site in San Antonio, Texas. Airplane #23, the first 787 to undergo change incorporation, on Friday flew from Everett, Wash., to San Antonio on a ferry flight. During change incorporation, airplanes that are not part of flight test are configured to conform with the standards established as part of type certification efforts. Refurbishment of three of the six 787 flight test airplanes also will take place in San Antonio after completion of flight test activities.

"The 787 team is thrilled to have the expertise and enthusiasm of the San Antonio team focused on getting these airplanes ready for delivery to our customers," said Scott Fancher, vice president and general manager of the 787 program.

The current plan is for six Dreamliners to complete change incorporation and refurbishment in San Antonio. Three will complete change incorporation and three airplanes will be refurbished after flight test is complete. However, the plan is flexible and could accommodate additional 787 production needs as flight test is completed and airplanes are prepared for delivery. The work will be performed from March 2011 through 2013.

"We continuously look for ways to leverage the strength of the Boeing enterprise, taking advantage of the team and the skills we have across the company," said Fancher. "San Antonio specializes in modification work and has the capability and capacity to get the job done. The team was a natural choice."

Some of the work done in San Antonio will include installing electronic and mechanical equipment, completing software upgrades, testing functional systems, and removing and reworking wiring or equipment that needs to be updated to current configuration requirements. Approximately 450 employees will be hired on a temporary basis to join with 1,700 experienced workers at the site to complete the work.

"Everyone on our team is excited to join the 787 program," said Kevin Devine, vice president and general manager of the San Antonio site. "This airplane is about as advanced as you can get and there are high expectations tied to this work package. I am confident that our team will get the job done."

Currently, there are about 1,500 employees at Boeing's San Antonio site performing maintenance and modification work on the following programs: KC-135 Programmed Depot Maintenance, KC-135 Global Air Traffic Management, C-17 Globemaster III Sustainment Partnership and the C-130 Avionics Modernization program.

There are other changes coming to the 787 flight test fleet...actually just one airplane. ZA004, which was to have the package "B" Trent 1000 engines installed last month will now have those engines installed between March 18th and April 6th.


Lastly, the 787 flight test fleet went over the 3,100 flight test hour mark yesterday when ZA003 completed a 2 hour and 10 minute test flight. It is epected that ETOPS testing should begin late this month and carry on into July.

Guy Norris: ZA005 heading to Puerto Rico

As I had mentioned earlier, ZA005 is flying to Aguadilla, Puerto Rico. At the time I wasn't sure what the test objectives are for ZA005 but Guy Norris has revealed that it is heading down to the Caribbean to undertake take off and landing tests. Boeing had the aircraft in New Mexico the last couple of days doing take off and landing tests at high altitude airport in Albuquerque. The airport at Aguadilla is at sea level.

Guy also goes into a flight test fleet update and states that ZA003 should be flying very soon as well. ZA006 is undertaking ground tests and should be flying again soon though no date is evident.

Guy Norris: Tropical Test for 787

787 Round Up

With Boeing's earnings call schedule for tomorrow, it is expected that there will be a lot of questions surrounding the 787 (schedule, certification, production and deliveries and on and on). Scott Hamilton has a nice update on his blog. One item he highlights is the ramp up to 10/months. He opines that Boeing will have trouble reaching that rate by the end of 2013 and feels that end of 2014 or into 2015 is more realistic.

Indeed it is looking that ramp up is going to be an issue. Boeing just started work on LN 32 (ZA235 for Air India) and LN 33 (ZA179 for JAL) won't be started until January 31st and LN 34 (ZA380, the first 787 for China Southern) will start final assembly on Feb. 14th. That's a 2/month production rate though I do expect that as the years wears on, this rate will increase (to what I don't know). You can read more of Scott Hamilton's post below:

Scott Hamilton: Odds and Ends: Big week for EADS, Boeing

In the same vein, Aviation Week reports Guy Norris and Mike Mecham wrote an extensive article regarding the 787 schedule. The main concerns remain what additional testing does the FAA require especially for ETOPs out of the box certification. The FAA has told Boeing that as it currently stands, the 787 won't get ETOPs certification until Boeing can prove the 787s reliability in light of the fire on ZA002 and the engine problems that Rolls Royce has encountered on the Trent 1000.

Aviation Week: Questions Remain About Boeing 787 Schedule

Boeing is trying to ramp up 787 test flights and currently has posted over 2600 of flight time over 850+ test flights. However, ZA003 and ZA006 have yet to resume test flights. It is unknown why they have not returned to test flights. Later this morning, ZA005 is schedule to make a test flight from Albuquerque, NM to Aguadilla, Puerto Rico. We'll see if this flight actually does occur.

Boeing's Busy News Day

The folks at Boeing have been having a pretty busy news weeks. First they announce the 787 return to certification test flight on Monday then yesterday they announce the new delivery start date for the 787. Today more news from Boeing.

They sold American Airlines 2 777-300ER. I think this is the first of many sales of that airplane to American Air. Then with Chinese President Hu visiting the US today, both US and China announced that China is buying $19bn of Boeing airplanes (200 in total). Trouble is that these planes we sold and booked between 2007 and 2010. Dominic Gates of the Seattle Times called the order "political window dressing" for the US-China summit.

The 787 continues with flight tests as ZA001, ZA002, ZA003 (returning to test flights) and ZA005 are all flying today. A very welcomed addition, ZA102, is scheduled to fly at about 2:10PM today (local time) in B-1 flight from Paine Field to Mosses Lake and back to Paine. This is the first production 787 to fly and will be used to help certify the ETOPs rating for the 787 which, according to Dominic Gates, maybe running into trouble.

Part of Boeing's plan for the 787 was to have it ETOPs certified right out of the box upon delivery to customers. With the fire last November the FAA is very reluctant to give Boeing that certification unless the company can demonstrate that the airplane can operate reliably over transpacific and transatlantic routes far from airports in case of an engine failure or any other mechanical problem that may force the aircraft to land early.

That certification is important to many customers who ordered the aircraft based on its fuel efficiency and it's ability to operate long distances from airports on point to point travel. Boeing indicated in its press release that they have built in additional margin for any additional testing that maybe required to prove the reliability of the 787 on long duration flights. Dominic Gates is reporting that the additional margin (thought to be about 3 months) may not be enough and that it may lead to additional delays though Boeing and the FAA remain in discussion about the scope of additional flight testing needed in order to achieve ETOPS out of the box certification. Boeing may add another production 787 to the ETOPS test flights in order to accomplish this.

Dominic Gates: FAA could spike Boeing's new 787 delivery schedule

The new schedule only answered one question: when is Boeing going to start 787 deliveries, but there are whole host of questions that need to be asked and answered before people would feel that Boeing has a handle on the remaining issues surrounding the 787. Flightblogger has got a list started but I would like the readers to add to those questions in form of a comment left on this posting.

Flightblogger: Quick Take: More questions than answers with eighth 787 schedule

ANA the launch customer, is obviously very concerned about this and is now asking Boeing for delivery assurances for the delivery schedule as well as detailed schedule for each of its 55 787s they have on order from Boeing. So far Qatar Airways is sticking with them and Boeing will be entering talks with Korean Air about their 787 delivery schedule (as it will with the other customers obviously).

Aviation Week: ANA to demand 787 delivery assurances

Now on top of all the news out of Boeing comes on tid bit on information from Airbus. They're apparently are having problems on A350. Word from Airbus is that they're delaying the start of final assembly on the first A350 from third quarter of 2011 to the end of 2011. Amazingly it seems they think they could conduct first flight by mid 2012 even accounting for a 9 month final assembly. Something there doesn't quite add up. Airbus has delayed delivery of the first A350 to Qatar Airways from early 3Q13 to late 4Q13. That's about a 6 month slip. I fear that there will be additional delays in store for this aircraft which may amount to an additional year delay in the delivery timeline.

Flightglobal: Airbus pushes A350 final assembly back to end-2011

Breaking: Boeing 787 resumes FAA Certification Flight Tests Today

Boeing announced a resumption of 787 certification flight test today in an email statement. Today Boeing had 4 787s flying (ZA001, ZA002, ZA004, and ZA005. The other two will be flying within the next one week:

787 Resumes Certification Flight Testing

Boeing has resumed certification flight testing of the 787 Dreamliner today. There are currently four airplanes back to flight status: ZA001, ZA002, ZA004 and ZA005. The others - ZA003 and ZA006 - are expected to be flying again within the next week or so.

Boeing is widely expected to announce the delivery schedule. With tonight's announcement of the resumption of certification test flights, I believe Boeing will announce the new delivery schedule sometime this week (Tuesday-Wednesday). Later this week I'm also expecting that ZA102 (LN 9) will take flight. This is the first production 787 to fly though the flight hours this airplane accumulates will not be counted towards certification flight testing (nonetheless I will try to keep track of the flights this particular airplane conducts).

787 return to certification testing in a week; ZA102 to fly in last two weeks of January

Now that the Holiday are over, Boeing is trying to pick up the pace for the lost time due to the fire on ZA002. Boeing has been flying ZA001 and/or ZA004 since January 3rd though they haven't been flying very long duration flights (longest so far is about 5 hours).

However, in the coming days we should see more 787 rejoining the test flight program though for the next one week at least these will be only Boeing test flights and certification test flights.

According to information from sources, ZA005 should be flying again on January 9th (Sunday), and ZA002 will be flying again on January 11th. ZA006 will fly on January 14th and ZA003 will be flying again on January 16th.

More importantly, ZA004 is projected to restart certification flight tests as early as January 14th with ZA001 and ZA006 projected to follow on the 15th, ZA002 on the 16th and ZA005 on the 18th.

Also of significance is that ZA102, the first production airplane to fly may fly as early as January 15th and as late as January 24th. This airplane is out on the flightline at Everett. It is around this time that Boeing will be releasing it's 2010 full year financial results so there would be more that will probably be siad about the schedule at that point though everyone is still waiting to hear about the revised delivery schedule from Boeing.

Note that this schedule is still a projected schedule and things can still change given Boeing continued discussions with the FAA.





I hope to learn more very soon.

One Year In....The 787 year in review.

For the last 12 months I've been giving a monthly update on the 787 flight test progress with the exception of last month. With the one year anniversary of ZA001's first flight and the suspension of 787 flight activities, it seems an appropriate time to review the 787 program and try and take a look ahead to see what awaits the 787. It has been a year of triumphs and heartache within the program and the current forecast for the program is, at best, overcast.

787 - December 15, 2009 to December 14, 2010

December 15, 2009 was a day that Boeing hoped that see the start of putting the troubles of the 787 program in the rear view mirror. It was a day that cloudy and rainy (typical Pacific Northwest weather). The first 787, ZA001, made an on time takeoff and flew for a little over 3 hours. ZA002 flew one week later in a flight that was shortened by issues with the main landing gear door and the nose gear. Nevertheless these initial flights started Boeing on the path of initial airworthiness flight trials. The 787 achieved IAT in mid January 2010 which allowed Boeing to conduct test with the other test flight airplanes as well as with engineers on board. This allowed for the expansion of the787 flight test envelope which would include stability and control testings, flutter testing and functionality and reliability testing of the airplane.

Boeing added airplanes to the test flight fleet with ZA004 flying in late February, 2010 and ZA003 flying in mid March 2010. The near term goal of the program was to achieve Type Inspection Authorization for the 787. This is the point that would formally kick off the certification program for the 787. This point of the program was expected to be achieved by mid to late February, 2010 but was not granted until April 20, 2010. This was a major indicator that the program may suffer delays to the delivery schedule yet again. During this period Boeing had successfully test the 787 wing to the ultimate load limit test on ZY997, the static test airframe. This was a major certification test point that Boeing needed to accomplish given the issues that Boeing had found almost a year earlier with the side of body join and the weakness that was discovered.

Boeing continued testing throughout the spring and summer of 2010. They seemingly hit a very good flight test pace during late May/early June only to see the number of flight and flight hours flown to drop off a month later and then recover later in the summer. Progress was made in September through the early part of November with significant flight hours being posted especially with the GEnx powered 787s that had finally joined the flight test program. However there were set back to flight testing (and production) due to the time needed to inspect the horizontal stabilizers on all 787s due to Alenia's workmanship issues. Boeing needed to spend precious time and resources to inspect and conduct any repairs on the aircraft that were built and/or flying. Still despite the Alenia debacle, Boeing was still on track to deliver the 787 by end of 2010 until an early August Trent 1000 engine test in Derby, UK took a bad turn and the engine had an uncontained failure of it intermediate pressure turbine.

This was a major setback for Rolls and Boeing as it threw the entire schedule into doubt. Indeed, the engine that failed was due to be installed on ZA102 (LN 9) which was to be used for flight tests of production standard aircraft. Boeing had to delay delivery to mid February because of the unavailability of an engine for ZA102 within the needed time frame to start flight tests on this aircraft.

Still Boeing said they were confident in Rolls Royce's hardware and software fixes to prevent a recurrence of the failure and Boeing continued with flight and ground testing of the 787 through early fall until Nov. 9th.

ZA002 was flying a long duration test flight with FAA personnel aboard testing the nitrogen generating system (part of the fuel inerting system) and was on final approach to an airport in Laredo Texas when a fire erupted in the lower electronics bay near the left wing. The fire was out after about 30 seconds but the power panel where the fire originated was destroyed and the aircraft had experienced power distribution problems while in the process of landing. An emergency was declared (apparently after landing) and the crew and test personnel evacuated the aircraft using the emergency slides.

The problems that lead to the fire in the P100 power distribution panel are now well known but now at this point, one year after the first 787 flew the 787 schedule is in shambles. The aviation world is waiting for Boeing's revised schedule. The 787 has had more than its fair share of problems and delays since it was launched in 2004 and there's nothing to say that there won't be any more issues when Boeing and the FAA resumes flight testing.

Boeing is still encountering supplier and production issues and probably will continue to see sporadic halts to part deliveries into Everett. Clearly there is still plenty of issues that need to be cleaned up so that Boeing can start deliveries of the 787 and ramp up production. However, the aviation world is now waking up to the fact in light of problems in various aircraft programs (A380, 787, A400M, F-35, and the A350) that the old model that aircraft manufacturers used to develop, design, test and produce high technology aircraft is out the door. Robert Wall of Aviation Week summed it nicely in a blog post a week ago: "Skeptics quip that Airbus is effectively fighting the last war, and that the only thing it is assuring is that it will invent a whole new series of missteps. If that turns out to be true, then perhaps it is time to put to bed the idea of accelerating development cycles on major products and just learn to live with the fact that the gestation period for a major civil aircraft program is eight years or longer."

Guy Norris: Another brief 787 flight

Guy Norris says that two 787s will fly briefly on Saturday, Nov. 20th. ZA003 will fly from Everett to Boeing Field while ZA004 will fly in the opposite direction going to Everett from Boeing Field.

ZA004 will be going to Everett to get some routine maintenance accomplished. This maintenance work was preplanned. ZA003 is expected to resume ground tests at Boeing Field. ZA001, ZA005 and ZA006 are also conducting ground tests until they all can have clearance to resume test flights.

Lastly, ZA102 which is the first production 787 to fly will be rolled out of 40-24 around the end of the month according to Guy. It would be fitted with the package "A" Trent 1000 engines and is schedule to fly in December depending on what happens with the fire investigation. Even if it doesn't fly it could still conduct ground test as well as taxi tests.

Guy Norris: 787 to fly again (briefly) on Saturday

Ten Months In...

The 787 test flight program reached milestone yesterday with 2,000 flight test hours accumulated in the 10 month old flight test program. The milestone was reached when ZA002 flew a 20 minutes test flight to Moses Lake Airport. However, through the last half of September and the first half of October there has been a very noticeable slowdown in the flight test program. In period from Aug. 15 to Sept. 14th, Boeing posted 362.5 flight hours on the 787 spread across 121 flights. From Sept. 15th to Oct. 14th, the 787s flew only 165 hours on 71 sorties. That's a reduction of over 54%. With ZA004 being out a month starting in November, Boeing will have to depend on the remaining three airplanes sustain the flight test program.

Boeing still has over 1,100 test flight hours to complete. The 787-Trent 1000 flight test fleet achieve another milestone by reaching 75% of the required (2,430) flight test hours. That means that the Trent 1000 flight test fleet has a little over 600 flight test hours to complete certification. Boeing says it has completed over 65% of the required testing conditions thus far.

Next month Boeing plans to change out the engines on ZA004 from the current Trent 1000 with package "A" to the package "B" powerplants. The change out should take about a month including ground testing and this airplane will be back in the air sometime in December. It does look like that the first few Trent powered 787s delivered to ANA will be the package A versions though I'm not sure when Rolls Royce will start delivering the package "B" to Boeing.

In the meantime Boeing has flown the Trent 1000 aircraft fairly aggressively in the last few days but I do still believe that they still have a long road ahead of them despite being almost three quarters of the way through the flight test program. If Boeing can fly the four test airplanes about six and a half hours a day for the next three months, they can achieve certification of the Trent powered 787s a month before first delivery. The GE powered airplanes are over 27% done with their test flight program but currently both airplanes are in lay ups and have not flown since early October. I'm still trying to find out when those airplanes are planned to return to the air.

While the test flight program continues on, Dominic Gates of the Seattle Times reported on the 787 that are piling up outside on Everett's flight line:

Dominic Gates: Boeing 787s stack up at Paine Field awaiting FAA approval

ZA102, the first production airplane to fly is now slated to have it's first flight around November 24th as the aircraft continues its final fitting out before being rolled out, presumably early next month.


Boeing Photo

Lastly, the 747-8I program achieved a milestone itself when the first airplane entered final body join. This aircraft should roll out at the end of this year or early next year with the flight test program due to start in early 2011.

Guy Norris has a blog post out that also details the 747-8F test flight program thus far:

Guy Norris: 747-8I Comes Together

Here's Boeing's Press Release:

Boeing Joins Fuselage Sections for First 747-8 Intercontinental

EVERETT, Wash., Oct. 15 /PRNewswire/ -- Boeing (NYSE: BA) moved closer this week toward completing assembly of the first 747-8 Intercontinental as mechanics in Everett, Wash., loaded the forward and aft fuselage sections to join with the wing and center section.

The 747-8 fuselage is 250 feet 2 inches (76.3 meters) long, which is 18 feet 4 inches (5.6 meters) longer than the 747-400. The stretch provides space for 51 additional seats to accommodate 467 passengers in a typical three-class configuration and offers 26 percent more cargo volume.

"Final body join is an important milestone for the 747 program," said Pat Shanahan, vice president and general manager of Airplane Programs in Boeing Commercial Airplanes. "It is a major step toward completing the structural integration and building out our all-new interior. We now have the first real look at the size and distinctive shape of the 747-8 Intercontinental. This is going to be a superb airplane for our customers both from an aesthetic and a performance perspective."

The 747-8 is the new high-capacity 747 that will give airlines the lowest operating costs and best economics of any large airplane while providing enhanced environmental performance. The airplane also features a 787 Dreamliner-inspired interior that will offer passengers a greater feeling of space and comfort.

The 747 program has orders for 109 747-8 Freighter and Intercontinental airplanes. Thirty-three of those are for the 747-8 Intercontinental, with orders coming from Lufthansa, Korean Air and eight VIP customers. The first 747-8 Intercontinental delivery is scheduled for late 2011 to a VIP customer.

787 keeps movin' along

As the time to first delivery draws closer, Boeing is ramping up both production as well as the pace of flight testing.

Flight Testing

The 787 flight test fleet is closing on 2000 flight hours flown, they can potentially break through that mark today. The Rolls Royce powered 787s got a real work out on Oct. 12th flying almost 24 flight hours during the day and breaking through the 1800 flight hour mark for the RR/787 flight test combination. Hopefully this signals a push to accumulate the remaining 35% flight test requirements needed to certify the Rolls powered 787s. Boeing has completed almost 75% of the require flight test hours needed to certify the Trent 1000 powered 787s so they are getting close.

While the first four 787s are being pushed, ZA005 is at Everett for some standard inspections as well as fuel transfer tests. ZA006 remains at Boeing Field going through the post first flight lay up where additional flight test instrumentation is being installed. I haven't heard when those two airplanes will be flying again. Currently about 27% of the GEnx/787 flight test hours have been flown.

ZA102 is now scheduled to fly around November 24th instead of November 9th though that date may change. This will be the first flight of a production standard 787 with a full customer interior. Both ZA101 and ZA102 have its Trent 1000 engines. ZA101 will undertake ground testing though I'm not sure if it has a customer interior as well.

Next month ZA004 will down for about a month while it gets new Trent 1000 engines with the package "B" improvements meant to bring the engines to within 1% of the promised SFC (specific fuel consumption) that Rolls Royce promised to its customers.

Production

As the flight test wring out the 787 for delivery, Boeing is slowly ramping up 787 production. Currently ZA230 will moved out of position 4 in building 40-26 and the line should pulse on October 15th but the next airplane ZA233 (LN 29) won't be loaded into position 1 until October 26th. I'm still trying to find out why the 11 day delay. ZA234 (LN 30, a 787 for Air India) is due to start final assembly 9 days later. This indicates that Boeing is attempting a 9 to 10 day run with each airframe is in each of the 4 assembly positions 9 to 10 day. This translates to a final assembly run for each 787 of about 36 to 40 days in building 40-26. At that rate, Boeing should be at ZA236 (LN 35, the 35th 787 being built is for Air India) by the end of the year though they will have 30 787s built and out on the flightline.

Speaking of the flightline, the parking spots for airplanes at Everett are getting full. So full that Boeing is now parking airplanes in a small ramp area in fron of the Future of Flight Museum. According to Matt Cawby, Boeing has leased out space at Everett near the air control tower as well asto the south of the asembly halls in order to store built but undelivered 787s.

Lastly, Flightblogger took a trip to 787 suppliers in Asia and has put up an excellent post of the 787 suppliers in Korea with some great photos. It is a great read.

Flightblogger: From Busan to Boeing: 787s Asian Supply Chain Part 1

Boeing Statement on ZA006 First Flight

Boeing Photo

Boeing released a statement announcing the first flight of the final test 787. However the first test flight was cut short due to a cooling fluid issue according to a Tweet by Flightblogger. The press release doesn't mention the flight being cut short. It mentions the flight lasting a little over an hour as well as reviews the 787 testing to date. Over 65% of the test conditions needed to certify the Rolls Royce powered 787 have been completed according to Boeing. Boeing has also completed 15 cycles on the fatigue test air frame (ZY998) and need to complete 10,000 by the time first delivery is made to ANA in mid February. Boeing is also looking to increase the production of 787s. The 28th 787 (ZA232) to be built just entered final assembly and the next one, ZA233, will enter final assembly 10 days later on Oct. 14th. This could mean that Boeing is attempting a 3/month production rate. Because of the production 787 already built, Boeing has started to store 787 in an area called Kilo North which is a newly constructed ramp area just south of the Future of flight Museum. Three 787s (ZA150, ZA151, and ZA176) were moved to this area over the weekend.

Flightblogger also has a couple of posting up with regards to today's flight:

Flightblogger: Sixth and final 787 test aircraft completes abbreviated test flight

Flightblogger: Liquid cooling squawk tied to abbreviated ZA006 first flight

Sixth Boeing 787 Makes First Flight, Testing Program Making Good
Progress

EVERETT, Wash., Oct. 4 /PRNewswire/ -- The final Boeing (NYSE: BA) 787 Dreamliner to join the flight test fleet made its first flight today from Paine Field in Everett, Wash. The airplane, ZA006, is the second 787 equipped with General Electric GEnx engines to fly.

Captains Christine Walsh and Bill Roberson were at the controls during the 1 hour and 4 minute flight. The airplane landed at Boeing Field at 12:45 p.m. (Pacific time).

"It's great to have our last flight test airplane join the fleet," said Scott Fancher, vice president and general manager of the 787 program. "We have been focused on completing the testing required for certification of the 787 with Rolls-Royce engines, because that is the first model we deliver. A great deal of the testing that we've done also applies to the 787s with GE engines and won't need to be repeated," said Fancher.

There is, however, a smaller portion of testing that is unique to the engine/airframe combination. In general, this portion includes noise testing, extreme weather operations, function and reliability, and extended operations. In addition, testing to verify the airplane handles the same regardless of engine type and that the systems work on both models is required.

Some additional flight tests will be performed on one of the production airplanes, the ninth 787 to be built, but it is not considered a full-time member of the flight test fleet.

787 Testing Progress Report

In addition to achieving first flight of ZA006, the Boeing test team has completed a number of flight test milestones in recent weeks.

Boeing wrapped up a series of natural and artificial icing tests, meeting all requirements with no changes required. Pilots reported that the airplane continues to handle well even in the presence of ice.

Flight loads survey testing, which demonstrates the pressure distribution on the airplane structure throughout the phases of flight in a variety of configurations, also has been completed. The team conducted this testing on ZA004 primarily at the airport at Victorville, Calif. Analysis of this testing continues.

A dramatic series of tests that stress the airplane's brakes, called maximum brake energy testing, was completed in late September at Edwards Air Force Base, also in California. ZA001 conducted this testing as well as a series of extreme takeoff and landing conditions including minimum takeoff speed testing. Earlier in the month, ZA001 completed wet runway testing at Roswell, NM.

ZA003 flew to Glasgow, Mont., to complete community noise testing. All results were within expectations.

As a result of these tests and others, all takeoff performance and handling characteristics testing is complete for the initial version of the 787. Additional testing will be required for 787s equipped with GE engines.

The 787 flight test program has logged more than 1,900 hours over 620 flights and completed more than 65 percent of the flight test conditions for 787s with Rolls-Royce engines.

Equally important to the testing required in the air is the ground testing required to certify a new airplane. Boeing has completed well over 4,000 hours of ground testing on the same airplanes that are in the flight test program.

In addition, fatigue testing has started at a test rig in Everett. Fifteen flights have been simulated. Federal regulations require Boeing to conduct twice as many flight cycles as any airplane in revenue service. Boeing plans to have completed 10,000 flight cycles prior to first delivery.

"We continue to be extremely satisfied with the performance of the 787 in its testing operations," said Fancher. "This airplane handles wonderfully and will be a valuable tool for our customers."

How long ZA006 will be out because of the issue that cropped up during flight is unknown at this time.

What are the 787s doing?

Well some of you reading this blog might be wondering about the activity (or lack there of) of test flights on the 787 test fleet. Here's a run down:

ZA001 - Having it's left engine changed (reason unknown); should return to flight around 10/5
ZA002 - In ground tests; should return to flight around 10/5
ZA003 - Maintenance; should return to flight on 9/30 (tomorrow)
ZA004 - Thrust reverser and misc. engine upgrades and additional instrumentation being added; should return to flight on 10/9
ZA005 - Engine change; should return to flight on 10/12
ZA006 - Undergoing flight readiness review for first flight; first flight on 10/4 (not 10/2 anymore)

Interestingly, ZA006 is in the paint hangar for an unknown reason but is still scheduled for its first flight.

Flightblogger, in between tours of various 787 supplier facilities, had time to put up a 787 post.

Some notable news:

• ZA101 (LN 8) has received its Trent 1000 engines
• ZA102 (LN 9) performed gear swing tests
• ZA102 has received a partial passenger cabin (between doors 1 and 2 and another section between door 3 and 4).
• ZA001 has successfully completed the max energy RTO tests
• 787 production is set to resume after this weekend with LN 28 (ZA232) for Air India set to start final assembly. This should mark the start of production at just under 3/month.

You can read more in his blog:

Flightblogger: 787 News in Brief: Trent 1000s, ZA006 first flight, float concludes, 787s 8 & 9, RTO in the bag, plus 737 and 747-8

Guy Norris also has a 787 update on the Aviation Week blog roll Things With Wings. He elaborates on ZA006's road to first flight as well as on the activities surrounding the other 5 test flight airplanes.

Guy Norris: Second GE 787 Set to Fly

Until the 787's are back in the air again, here a re some Boeing videos on the 787 for your viewing pleasure:

All Videos Courtesy of Boeing